WO2019094620A2 - Traitement de flux de queues à l'aide d'une ou de plusieurs doses de chaux, et systèmes et procédés associés - Google Patents

Traitement de flux de queues à l'aide d'une ou de plusieurs doses de chaux, et systèmes et procédés associés Download PDF

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Publication number
WO2019094620A2
WO2019094620A2 PCT/US2018/059863 US2018059863W WO2019094620A2 WO 2019094620 A2 WO2019094620 A2 WO 2019094620A2 US 2018059863 W US2018059863 W US 2018059863W WO 2019094620 A2 WO2019094620 A2 WO 2019094620A2
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WO
WIPO (PCT)
Prior art keywords
mixture
stream
tailings
lime
dosage
Prior art date
Application number
PCT/US2018/059863
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English (en)
Other versions
WO2019094620A3 (fr
Inventor
Michael John TATE
Jared Ira LEIKAM
Jesse Wayne FOX
Nikolas Andrei ROMANIUK
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Graymont Western Canada Inc.
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Publication date
Application filed by Graymont Western Canada Inc. filed Critical Graymont Western Canada Inc.
Priority to AU2018366144A priority Critical patent/AU2018366144B2/en
Priority to CA3089959A priority patent/CA3089959A1/fr
Publication of WO2019094620A2 publication Critical patent/WO2019094620A2/fr
Publication of WO2019094620A3 publication Critical patent/WO2019094620A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/52—Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities
    • C02F1/5281—Installations for water purification using chemical agents
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/001—Processes for the treatment of water whereby the filtration technique is of importance
    • C02F1/004—Processes for the treatment of water whereby the filtration technique is of importance using large scale industrial sized filters
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/38—Treatment of water, waste water, or sewage by centrifugal separation
    • C02F1/385—Treatment of water, waste water, or sewage by centrifugal separation by centrifuging suspensions
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/52—Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities
    • C02F1/5236—Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities using inorganic agents
    • C02F1/5245—Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities using inorganic agents using basic salts, e.g. of aluminium and iron
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/52—Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities
    • C02F1/54—Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities using organic material
    • C02F1/56—Macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C02F11/121—Treatment of sludge; Devices therefor by de-watering, drying or thickening by mechanical de-watering
    • C02F11/127—Treatment of sludge; Devices therefor by de-watering, drying or thickening by mechanical de-watering by centrifugation
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/10—Nature of the water, waste water, sewage or sludge to be treated from quarries or from mining activities
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2209/00—Controlling or monitoring parameters in water treatment
    • C02F2209/06—Controlling or monitoring parameters in water treatment pH

Definitions

  • This application relates to systems and methods for promoting dewatering of tailings streams using lime.
  • tailings streams from oil sands or mining operations are mixed with a polymer and one or more dosages of lime additive to promote dewatering of the tailings streams.
  • a tailings slurry defined as whole tailings, is produced as a byproduct of the CHWE process, and can include water, sand, clay, and residual bitumen particles that are suspended in the extraction water.
  • Coarse sand particles e.g., > 44 pm
  • coarses finer particles
  • a portion of the remaining fines, water, and residual bitumen form a slurry that is about 10-15% solids by mass, which after a number of years can settle to be about 20-40% solids by mass.
  • FFT fluid fine tailings
  • MFT mature fine tailings
  • FIG. 1 is a schematic flow diagram of a tailings dewatering system, configured in accordance with embodiments of the present technology.
  • FIG. 2A is a schematic flow diagram of a tailings dewatering system, configured in accordance with embodiments of the present technology.
  • FIG. 2B is a schematic flow diagram of an extraction process of the tailings dewatering system, configured in accordance with an embodiment of the present technology.
  • FIG. 3 is a block diagram of a method of dewatering a tailings stream, configured in accordance with an embodiment of the present technology.
  • FIG. 4 depicts a flow chart 400 for dewatering a tailings stream, configured in accordance with an embodiment of the present technology.
  • FIGS. 5A-5C are images of experimental results related to treatment of tailings stream samples with and without lime over a period of time, configured in accordance with embodiments of the present technology.
  • FIG. 6 is an image of experimental results related to treatment of tailings stream samples using various concentrations of lime, in accordance with embodiments of the present technology.
  • FIG. 1A is a schematic flow diagram of a tailings dewatering system 100 ("system 100").
  • the system 100 includes a tailings holding reservoir 102 (e.g., a pond, diked area, tank, etc.) including tailings 103 contained therein, and a lime holding reservoir 104 (e.g., a tank) including a lime slurry 105 (e.g., a lime additive) contained therein.
  • the tailings 103 can originate from oil sands operations, and generally include the remains of the oil sands after the extraction of bitumen therefrom.
  • tailings can include whole-tailings (WT), thin fluid tailings (TFT), fluid fine tailings (FFT), hydro-cyclone overflow or underflow and/or mature fine tailings (MFT) (referred to collectively as "tailings").
  • tailings can originate from the extraction of minerals (e.g., copper, gold and/or uranium) from other mining operations.
  • the tailings 103 can come from the tailings holdings reservoir 102 or directly from another process 101 (e.g., an extraction process) without being routed through the tailings holding reservoir 102.
  • the tailings 103 in the tailings holding reservoir 102 can be slightly alkaline, having a pH level of about 7.5-8.5, and the lime slurry 105 in the !ime holding reservoir can be alkaline, having a pH level greater than or equal to about 12.0.
  • the tailings 103 is combined with a dosage of the lime slurry 105 in a first vessel 106 (e.g., a mixer) to produce a lime-tailings mixture 107 having a first composition and a pH equal to or less than about 12.0.
  • a first vessel 106 e.g., a mixer
  • the pH of the lime-tailings mixture 107 may be equal to or less than about 1 1.9, 1 1.8, 1 1.7, 1 1 .6 or 1 1 .5.
  • the amount of soluble calcium levels of the lime-tailings mixture 107 may be equal to or less than 30 mg/L, 25 mg/L, 20 mg/L.
  • the dosage of lime slurry 105 reacts with the tailings 103 to remove at least a portion of the bicarbonates present in the tailings.
  • the lime-tailings mixture 107 can then be diluted (e.g., with process water) to contain about 3% solids by weight. Dilution of the lime-tailings mixture 107 can help promote better flocculation and speed the settling rate of flocculated solids.
  • the lime-tailings mixture 107 is then combined with a flocculant 1 10. This can occur in-line via line 1 13a and/or in a second vessel 108 (e.g. , a thickener or holding reservoir) via line 113b.
  • the lime-tailings mixture 107 can separate (e.g. , via settling) over a period of time to produce a first stream 109 substantially comprising solids, and a second stream 111 substantially comprising process water.
  • the addition of the flocculant 110 to the lime- tailings mixture 107 is based on (a) the first stream 109 being greater than 30% solids by weight and/or (b) the second stream 11 1 being less than 3% solids by weight. For example, if the first stream 109 has a solids content less than 30% solids by weight, the amount of flocculant 110 added to the lime-tailings mixture 107 may be increased. Additionally, if the second stream 11 1 has a solids content greater than 3% solids by weight, the amount of flocculant 110 added to the lime-tailings mixture 107 may be increased.
  • the second stream 111 comprises water including solids levels at less than 3% and containing sodium hydroxide particles that have been formed as a byproduct of reacting the lime slurry 105 with bicarbonates from the tailings 103.
  • the second stream 11 1 can be directed toward and used to promote bitumen extraction.
  • the first stream 109 corresponding to a mixture (e.g. , a second mixture) having a second composition, is removed from a bottom portion of the vessel 108 and can be routed to further downstream processing or a disposal area (e.g. , a pit or diked disposal area), in some embodiments, downstream processing can include drying (e.g.
  • a disposal area e.g. , a diked disposal area
  • reclamation area may be, for example, water capped using Permanent Aquatic Storage Structure (PASS) technology.
  • PASS Permanent Aquatic Storage Structure
  • the tailings 103 can include water, sand, clay, and residual bitumen particles that are suspended in the extraction water.
  • the tailings 103 can be obtained from taiiings ponds or steady-state extraction processes from oii sands or mining operations.
  • the tailings 103 may be stored in a tailings pond and include a settled solids content of about 10-45% by weight (e.g. , wet weight). More specifically, the tailings can include a mineral solids content from about 5-40%, a bitumen content from about 0-3%, a ciay content from about 40-100%, and a pH from about 7.5-9.0.
  • the tailings 103 may undergo upstream processing (e.g. , prior to being held in the holding reservoir 102), such as cyclone separation, screen filtering, thickening and/or dilution processes.
  • upstream processing e.g. , prior to being held in the holding reservoir 102
  • the tailings 103 entering the mixer 106, after potentially being combined with recycled water 122, can be diluted to be as low as 3% solids by weight.
  • the solids content is preferably above 10% by weight.
  • the iime slurry 105 in the lime slurry holding reservoir 104 includes a liquid (e.g., water) and a lime additive that can be less than 15% by weight of the lime slurry, less than about 10% of the lime slurry, or less than about 5% of the lime slurry.
  • the lime slurry additive 105 stored in the lime holding reservoir 104 can include inorganic materials that provide divalent (e.g., calcium) cations.
  • the lime slurry 105 can comprise a lime product including hydrated lime (e.g. , calcium hydroxide (Ca(OH) 2 )), slaked quicklime (e.g. , calcium oxide (CaO)), and/or enhanced hydrated lime.
  • the enhanced hydrated lime can include particles with an average Brunauer-Emmett-Teller (BET) surface area exceeding 30 m 2 /g.
  • BET Brunauer-Emmett-Teller
  • Other specifications and characteristics of enhanced hydrated particles are described in U.S. Patent Application No. 15/922,179, filed March 15, 2018, the disclosure of which is incorporated herein by reference in its entirety.
  • the lime slurry can include dolomitic lime (e.g. , lime including at least 25% magnesium oxide on a non-volatile basis), other lime-containing materials, or a combination of quicklime, limestone, hydrated lime, enhanced hydrated lime, dolomitic lime, and/or other lime- containing materials.
  • limestone e.g.
  • the taiiings 103 and the lime slurry additive 105 are combined in the mixer 106 to produce the lime-tailings mixture 107 having the first composition.
  • the mixer 106 can include means to agitate the lime-tailings mixture 107, such as rotating blades.
  • the mixer 106 can include a static mixer, a dynamic mixer, or a T mixer.
  • the residence time in the mixer 108 for particles of the lime- tailings mixture 107 can be, for example, at least about five seconds, at least about 60 seconds, at least about five minutes, at least about 10 minutes, or at least about 20 minutes.
  • the mixer 106 mixes the tailings 103 and lime slurry 105 to ensure the lime-tailings mixture 107 exiting the mixer 106 is well mixed and has a desired pH at or slightly below about 12.0, 1 1 .8 or 1 1 .5.
  • a pH at or below 12.0 for example, can aid in minimizing the bicarbonates present in the tailings 103.
  • a pH at or below 12.0 generally does not provide soluble calcium cations prior to the polymer 1 10 being added in a subsequent step. This minimizes the concentration of soluble calcium in the second stream 1 1 1 .
  • the soluble calcium cations in stream 1 1 1 comprise about 100 mg/L, 90 mg/L, 80 mg/L, 70 mg/L, 60 mg/L, 50 mg/L, 40 mg/L, 30 mg/L, 20 mg/L, about 10 mg/L, or less.
  • the pH of the lime-tailings mixture 107 at the outlet of the mixer 106 can be measured and used to control the pH of the lime-tailings mixture 107 by (a) increasing or decreasing the feed rate of the incoming !ime slurry 105, and/or (b) increasing or decreasing the residence time of the tailings 103 and lime slurry 105 in the mixer 106.
  • the lime-tailings mixture 107 is directed to the second vessel 108 where it is combined with the flocculant 1 10.
  • the flocculant can include one or more anionic, nonionic, cationic, or amphoteric polymers, or a combination thereof. These polymers can be naturally occurring (e.g., polysaccharides) or synthetic (e.g., polyacrylamides).
  • the flocculant 1 10 can be added as a part of a slurry, which may comprise about 0.4% by weight flocculant and process water and/or makeup water. Typically, at least one component of the flocculant 1 10 will be high molecular weight (e.g., up to about 50,000 kD).
  • the flocculant can promote thickening (e.g. , increasing the concentration of solids) of the iime-taiiings mixture 107 and allow solids from the lime-tai!ings mixture 107 to settle faster compared to if the lime-tailings mixture was treated only with a lime additive or only with a flocculant.
  • the vessel 108 and the residence time of the lime-tailings mixture 107 in the vessel 108 can also promote thickening of the lime-tailings mixture 107 by aiding in the separation of the lime-taiiings mixture 107 into the first stream 109 and the second stream 1 11.
  • the vessel 108 decreases the amount of water that has to be removed by, for example, the dewaiering device 116 to obtain a cake having acceptable geotechnicai properties.
  • removing the second stream 111 from the first stream 109 can decrease cycle time of the overall dewatering process.
  • the system 100 can further include a control system 130.
  • the control system 130 can be used to control operation associated with the system 100.
  • Many embodiments of the control system 130 and/or technology described below may take the form of computer- executable instructions, including routines executed by a programmable computer.
  • the control system 130 may, for example, also inc!ude a combination of supervisory control and data acquisition (SCADA) systems, distributed control systems (DCS), programmable logic controllers (PLC), control devices, and processors configured to process computer-executable instructions.
  • SCADA supervisory control and data acquisition
  • DCS distributed control systems
  • PLC programmable logic controllers
  • control devices e.g., programmable logic controllers
  • control system as generally used herein refers to any data processor.
  • Information handled by the control system 130 can be presented at any suitable display medium, including a CRT display or LCD.
  • the technology can also be practiced in distributed environments, where tasks or modules are performed by remote processing devices that are linked through a communications network.
  • program modules or subroutines may be located in local and remote memory storage devices.
  • aspects of the technology described Anlagenow may be stored or distributed on computer- readable media, including magnetic or optically readable or removable computer disks, as well as distributed electronically over networks. Data structures and transmissions of data particular to aspects of the technology are also encompassed within the scope of particular embodiments of the disclosed technology.
  • the second mixture 109 can undergo further treatment(s), including one or more additional dosages of lime and/or floccu!ants.
  • Figure 2A which illustrates one such embodiment, includes a third vessel 1 12 (e.g., a second mixer) to which the second mixture 109 is routed to.
  • the second mixture 109 is combined with a second dosage of lime slurry 1 15 in a third vessel 1 12, e.g., via line 125a, to produce a mixture 1 17 having a third composition and a pH greater than about 12.0, 12.2, or 12.4.
  • the second dosage of lime slurry 1 15 can originate from the lime holding tank 104, a separate lime holding tank, or other means.
  • the mixture 1 17 is then moved to a dewatering device 1 16 to promote dewatering of the mixture 1 17.
  • the dewatering device 1 16 can include a centrifuge, and/or a pressure, belt or vacuum filtration system that separates the mixture 1 17 into a first stream 1 18 substantially comprising solids (e.g., a "cake") and a second stream 120 substantially comprising a centrate or a filtrate (e.g. , release water).
  • the first stream 1 18 may be combined with a lime slurry, e.g., via line 125b.
  • the mixture 1 17 can be placed on one or more pads in thin/thick lifts to consolidate and dry the solids content contained therein.
  • the second stream 120 can be directed to a pond and/or be used as a recycled stream 122.
  • the recycled stream 122 can be combined with (a) the tailings reservoir 102, e.g., via line 122a, (b) the tailings 103, e.g. , via line 122b, prior to being mixed with the first dosage of lime slurry 105, (c) the lime slurry reservoir 104, e.g., via line 122c, (d) the lime slurry 105, e.g. , via line 122d, prior to being mixed with the tailings 103, (e) the lime slurry reservoir 1 15, e.g.
  • the recycled portion of the release water can include soluble calcium cations previously injected as part of the lime slurry, and thus can decrease the amount of the first dosage of lime slurry 105 needing to be injected to the mixer 106.
  • the second stream 1 18 can be collected and transported using a truck, belt, pump, and/or other conveying system(s) to an external site (e.g., a temporary storage or reclamation area).
  • the second stream 1 1 1 can be directed toward and used to promote bitumen extraction.
  • the second stream 1 1 1 can be routed to an upstream process associated with extraction of bitumen from oil sands ore and be mixed with process water 126.
  • the process water 126 can be supplemented/treated with sodium particles (Na + ) to aid in releasing bitumen from the oil sands ore. Accordingly, one advantage of recycling the second stream 1 1 1 to treat the process water 126 is the ability to decrease any supplement addition of sodium particles.
  • the second stream 1 1 1 1 is at least slightly alkaline due to the excess hydroxide ions present therein, recycling the second stream 1 1 1 to the extraction process can increase the pH of the oil sand ore and thereby improve bitumen extraction efficiency.
  • Yet another advantage of recycling the second stream 1 1 1 is that heat is already present in the second stream 1 1 1 , and thus recycling requires less downstream heating requirements compared to using just the process water 126.
  • Yet another advantage of recycling the second stream 1 1 1 is removing the volume of the second stream 1 1 1 from the first stream 109 (i.e., the mixture having the second composition) that is sent downstream to the mixer 1 12 and the dewatering device 1 16.
  • Removing the second stream 1 1 1 maximizes the solids content of the first stream 109 and minimizes the overall volume of material that is sent to the dewatering device 1 16. This decrease in volume can increase overall throughput of the dewatering system 100, and decrease time and costs associated with operating the dewatering device 1 16.
  • the lime-tailings mixture 109 having the second composition is subsequently directed from the vessel 108 to the mixer 1 12 where it is combined with the second dosage of lime 1 15.
  • the lime slurry 1 15 used as the second dosage can include features generally similar or identical to the lime slurry 105 previously described and used as the first dosage.
  • the mixer 1 12 and processing conditions (e.g. , residence time) of the mixture 1 17 in the mixer 1 12 can include features generally similar or identical to the mixer 106 and processing conditions previously described.
  • the second dosage of lime slurry 1 15 is added to the lime-tailings mixture to increase the pH of the mixture 1 17 exiting the mixer 1 12 to be above about 12.0. At this pH, pozzolanic reactions can begin to occur and thereby chemically modify clay particles from the tailings of the mixture 1 17.
  • An advantage of the addition of a first dosage of lime, a polymer, and a second dosage of lime, as opposed to only a single dosage of lime (e.g., lime slurry 105), is the decreased cycle time of the overall dewatering process.
  • the combination of the lime-tailings mixture 107 and the flocculant 110 in the vessel 108 without the significant presence of soluble calcium ions can result in a quicker settling of solids of the lime-tailing mixture 107 in the vessel 108.
  • the bicarbonate does not limit the effectiveness of the second iime dosage to promote pozzolanic reactions, as may be the case if only a single lime dosage was used.
  • the mixture 1 17 is subsequently directed (e.g. , via gravity and/or a pump, from the mixer 1 12 to the dewatering device 1 16 or other treatment processes, e.g. , via a dewatering device bypass 1 19.
  • These other treatment processes can include, for example, thin/thick lift deposition, deep deposition, or water-capping technologies.
  • the dewatering device 1 16 can include a centrifuge, a filtration system and/or other similar systems that can provide a physical force on the mixture1 17 to promote dewatering and separate the mixture 1 17 into a centrate or a filtrate (e.g. , the release water 120) and a cake 1 18.
  • the centrifuge can include a scroll centrifugation unit, a solid bowl decanter centrifuge, screen bowl centrifuge, conical solid bowl centrifuge, cylindrical solid bowl centrifuge, a conical-cylindrical solid bowl centrifuge, or other centrifuges used or known in the relevant art.
  • the filtration system can include a vacuum filtration system, a pressure filtration system, belt filter press, or other type of filtering apparatus known in the relevant art that utilizes a desired filtration process.
  • the filtration system can include a Whatman 50, 2.7 micron filter and can subject the lime-tailings mixture to about 100 psig of air pressure.
  • the mixture 1 17 may be transferred to the centrifuge or filter immediately after the mixing process has completed in the mixer 1 12, or after a period of time (e.g. , a predetermined period of time).
  • the mixture 1 17 may, for example, be retained in the mixer 1 12 for one hour, 30 minutes, five minutes, or less.
  • the lime-tailings mixture may be retained for more than one hour (e.g. , one day, one week, one month, etc.).
  • the mixture 1 17 may be retained for any desired amount of time to ensure it has been modified enough for the centrifuge and/or filter to separate a sufficient amount of water from the solids in the mixture 1 17.
  • the mixture 1 17 can bypass the dewatering device 1 16 via stream 1 19 and instead be directed toward, for example, a tailings pond or settling area to allow the mixture 117 to dewater over time without the use of additional machinery.
  • the dewatering device 116 has a first outlet used to transfer the separated release water 120, and a second outlet that is used to transfer the separated cake 118.
  • the separated cake 1 18 is a solid (e.g., a soft solid) that is composed of the particulate matter found in the tailings, such as sand, silt, clay, and residual bitumen. The lime additive particles and some residual water typically do not get removed during the dewatering process.
  • the cake 1 18 can include at least 45% solids by weight. In other embodiments, the cake 118 can include at least about 60% solids, at least about 65% solids, at least about 70% solids, at least about 80% solids, at least about 85% solids, or at least about 90% solids. More generally, the cake 118 may include a greater percentage of solids by weight than the percentage of liquids by weight.
  • the separated release water 120 can include water found in the tailings 102, water used to dilute the tailings 102 prior to the thickener 108, water added with the flocculants, and/or water that may be found in the lime slurry 104.
  • the separated release water 120 may also contain some solid particulate matter (e.g., sand, silt, clay, residual bitumen, and lime additive) that is not separated from the release water 120 during the dewatering process.
  • the release water 120 includes less than about 10% solids by weight.
  • the release water can include less than about 5% solids, less than about 4% solids, less than about 3% solids, or less than 1 % solids.
  • the release water 120 includes a significantly greater percentage of water by weight than the percentage of solids by weight.
  • the release water 120 may be directed to a number of different applications.
  • the release water 120 may be (a) recycled back to the tailings treatment process, or (b) used to regenerate caustic soda (e.g., sodium hydroxide) in water utilized in the bitumen extraction process.
  • the release water 120 can be treated with carbon dioxide to reduce the pH and amount of soluble calcium cations present therein. This can be done via natural absorption of bicarbonates (e.g., by carbon dioxide present in the atmosphere), or by actively injecting carbon dioxide into the release water 120.
  • the release water 120 is recycled back to the tailings treatment process as the recycle stream 122
  • at least a portion of the release water 120 is recycled and added into the tailings holding reservoir 102 or the tailings stream 103 when being transferred to the mixer 106.
  • the recycled release water 122 mixes with the tailings 103 prior to or while being combined with the first dosage of lime slurry 105.
  • Adding the recycle stream 122 to the tailings stream 103 prior to the mixer 106 increases the pH level of the tailings 103 because the recycle stream 122 includes soluble calcium cations that were not removed during the dewatering process, and is thus alkaline.
  • the calcium ions in the recycle stream 122 readily react with bicarbonates present in the tailings stream 103 to form insoluble compounds that precipitate out of solution and can separate from the suspended tailings.
  • Using the recycle water 122 to reduce the amount of bicarbonates in the taiiings 103 reduces the amount of the lime slurry 105 needed for enhanced dewatering to occur, which in turn can reduce the cost of the overall dewatering process.
  • using recycle water 120 to increase the pH level of the tailings 103 can be omitted and the tailings dewatering system 100 may not use any portion of the release water 120 during the dewatering process.
  • the system 200 can include the control system 130, as previously described.
  • the control system 130 can be used to control operation of the system 200.
  • the control system 130 can control (e.g., regulate, limit and/or prevent) the flow of fluids ⁇ e.g., process 101 , tailings stream 103, lime slurry 105, lime- tailings mixtures 107/109/117, second stream 11 1 , cake 118, dewatering device bypass 119, release water 120, recycle stream 122, etc.) to and/or from different units (e.g., tailings reservoir 102, lime holding tank 104, mixers 106/112, vessel 108, dewatering device 116, etc.) of the system 200.
  • the control system 130 can control operation of individual units, such as the mixers 106/112 (e.g., controlling mixing speeds), and /or the dewatering device 1 16.
  • FIG. 3 is a block diagram of a method 300 of dewatering a tailings stream, configured in accordance with an embodiment of the present technology.
  • Process portion 302 includes providing a tailings stream including 3-40% solids by weight to a dewatering system (e.g., the systems 100 or 200).
  • the tailings stream can have a composition similar or identical to the tailings stream 103 previously described.
  • the taiiings stream may operate as a steady state system having a constant feed or as a batch stream in which taiiings are provided to the system at reguiar intervals.
  • Process portion 304 includes combining the tailings stream with a dosage of lime, such as quicklime, iimestone, hydrated lime, enhanced hydrated lime, or dolomitic lime, to the tailings stream to form a first mixture.
  • a dosage of lime such as quicklime, iimestone, hydrated lime, enhanced hydrated lime, or dolomitic lime.
  • Adding the dosage of lime to the tailings stream increases the pH of the tailings stream to or slightly below 12.0 such that bicarbonates present in the tailings stream begin to react with and be consumed by calcium cations from the dosage of lime.
  • Reactions 3 and 4 reduce the amount of soluble calcium cations avaiiable for cation exchange and pozzolanic reactions to occur, the concentration of carbon dioxide in the atmosphere is relatively low and limited by diffusion from the atmosphere into water. As such, Reactions 3 and 4 require longer periods of time to have an effect on the concentration of free calcium cations in the lime-tailings mixture under atmospheric conditions. Reactions 1 and 2, on the other hand, are limited only by the availability of carbonate ions in the lime-tailings mixture and occur significantly more readily than cation exchange or pozzolanic reactions, which means that there are very few free calcium cations available to react with clays in the tailings until the carbonate ions are largely depleted.
  • the pH level of the mixture will eventually approach about 12.0, or more particularly about 1 1 .8, and the concentration of carbonate ions in the mixture will approach zero. At this point, the number of free and soluble calcium cations in the water will increase.
  • the first mixture can optionally be combined with a flocculant.
  • the combination of the first mixture with the flocculant can separate into a first stream (e.g., first stream 109) comprising a second mixture, and a second stream (e.g. , second stream 1 1 1 ) significantly comprising water having sodium hydroxide particles.
  • the sodium hydroxide particles in the second stream are produced in part from Reaction 2 and can be removed from the dewatering process such that only the second mixture continues toward the dewatering device.
  • a second dosage of lime can be combined with the first mixture or the second mixture to produce a third mixture having a pH greater than about 12.0 (process portion 408).
  • the calcium hydroxide ions provided via the second lime dosage increase the pH of the third mixture and provide divalent cations that can modify and affect the stability of fine clay soils in the tailings.
  • the pH levels increase above 1 1 .5 the calcium cations from lime are more soluble due to the depletion of bicarbonates in process water and can replace cations such as sodium and potassium on the surface of clay soils.
  • pH levels increase above 12.0, a chemical modification of the clay's surface occurs by pozzolanic reactions.
  • pozzolanic reactions In pozzolanic reactions, soluble calcium cations from the lime react with silicic acid (Si(OH)4) and aluminate (AI ⁇ OH)4 " ) functional groups from the day materials to form calcium silicate hydrate (CaH2Si0 4 -2H20) and various aluminum hydrates, such as calcium aluminate hydrate. After being chemically modified, the fine clay particles grow in size, decrease their water layer, and can be separated from the water using a centrifuge or filter, as previously described. In some embodiments, the pozzolanic reactions may occur after the third mixture is centrifuged and/or filtered.
  • the lime additive may be a continuous flow of lime additive that is continuously added and mixed into the tailings stream.
  • the lime additive may be added and mixed into the tailings streams in individual batches.
  • the method proceeds to process portion 310, where the third mixture is dewatered by separating at least a portion of the solid material from the liquid components in the third mixture.
  • the dewatering process can comprise a centrifuge and/or filter to forcibly separate the solid material in the third mixture from the liquid components.
  • the centrifuge and/or filtration system provide a driving force that promotes dewatering the clay particles via cation exchange and pozzolanic reactions, as previously described.
  • the third mixture is dewatered in a dedicated disposal area by a process, such as thin/thick lift deposition, TRO, AFD, and/or PASS, where atmospheric drying and freeze/thaw treatment(s) to allow the third mixture to dewater over time without the use of additional machinery.
  • a process such as thin/thick lift deposition, TRO, AFD, and/or PASS, where atmospheric drying and freeze/thaw treatment(s) to allow the third mixture to dewater over time without the use of additional machinery.
  • the method 300 proceeds to produce a cake with a solids content of at least 40% solids by weight.
  • the solids in the cake are typically sand, silt, clay, residual bitumen, and the lime additive, along with any other solid particulate matter that is present in either the tailings and/or first and second dosages of lime.
  • the balance of the cake is composed primarily of water that was introduced in either the tailings and/or first and second dosages of lime.
  • the dewatering system also produces a release water stream that is formed from the tailings water from which the solids are separated.
  • Converting the solid material found in the oils sands tailings stream into a stream of cake that is at least 55% solids by weight enables significantly easier storage, transport and disposal of the solids compared to the solid materials trapped in suspension in the oil sands tailings stream.
  • FIG. 4 depicts a flow chart 400 for dewatering a tailings stream, configured in accordance with an embodiment of the present technology.
  • the flow chart 400 includes providing a tailings stream (block 402), and adding lime to the tailings stream to produce a lime-tailings mixture having a first composition (block 404).
  • the pH of the lime-tailings mixture having the first composition is then measured (block 406).
  • the system e.g., the control system 130
  • the first predetermined threshold may be a pH less than or equal to about 12.0, 11.8. or 1 1.5.
  • a pH at or below 12.0 for example, can aid in minimizing the bicarbonates present in the tailings 103, which can affect the rate of dewatering in the downstream process. If the measured pH is less than the first predetermined threshold, then the system may proceed without adjusting the amount of lime being added to the tailings stream in block 404.
  • the flow chart 400 further includes an optional step of combining the lime- taiiings mixture with a polymer.
  • the polymer can promote thickening of the lime-tailings mixture and allow solids from the lime-tailings mixture to settle faster compared to if the lime-tailings mixture was treated only with lime or only with a polymer.
  • additional lime is added to produce a lime-tailings mixture having a second composition different than the first composition (block 414), and the pH of the lime-tailings mixture having the second composition is then measured (biock 416).
  • the system may increase the amount of lime being added to the lime-tailings mixture in block 414 (block 420).
  • the second predetermined threshold may be a pH greater than or equal to about 12.0, 12.2 or 12.4.
  • a pH at or above 12.0 can promote pozzo!anic reactions, which can chemically modify clay particles of the lime-tailings mixture and thereby stimulate dewatering of the lime-tailings mixture.
  • the system may proceed without adjusting the amount of lime being added to the lime-tailings mixture in block 414.
  • the lime-tailings mixture having the second composition can be dewatered to produce a centrate (e.g., via centrifugation) or a filtrate (e.g., via pressure filtration), and a cake (block 422).
  • a centrate e.g., via centrifugation
  • a filtrate e.g., via pressure filtration
  • FIGS. 5A-5C are images of experimental results related to treatment of tailings stream samples with and without lime over a period of time, in accordance with embodiments of the present technology. More specifically, a comparison test was run to examine the difference between treating an FFT sample with and without lime coagulation. Each of the two FFT samples was diluted with process water to approximately 3% solids by weight. The sample on the left side of FIGS. 5A, 5B and 5C was coagulated with 1000 mg/kg h yd rated lime and flocculated with SNF A3331 polymer at a dose of 250 g/dry tonne FFT solids. The sample on the right side of FIGS. 5A, 5B and 5C was treated only with SNF A3331 polymer at a dose of 250 g/tonne FFT solids. Both sample conditions were simultaneously mixed multiple times by lowering a glass rod with a rubber stopper on the bottom through the mixture.
  • FIG. 5A shows the two samples during the final mixing
  • FIG. 5B shows the two samples a period of time (less than one minute) after the image of FIG. 5A was taken
  • FIG. 5C shows the two samples a period of time (less than one minute) after the image of FIG. 5B was taken.
  • the lime treated sample settled into a first (bottom) portion including ultra-fine particles of the FFT, and a second (top) portion including release water of the FFT.
  • the sample treated only with polymer does not exhibit the same settling rate, as FIG. 5C shows the FFT only slightly settled.
  • Example 1 illustrates in part that lime coagulation with poiymer floccuiation, as opposed to just polymer flocculation, can improve fines capture of FFT samples.
  • the mudline The time (in seconds) needed for the interface (referred to as "the mudline") between the release water and the settled solids of the mixture to reach 700 mL (70% of total height) was recovered to account for the rate of initial settling, and the mudline (in mL) was recorded after 30 minutes to attain the total capacity of settling that had occurred.
  • FIG. 6 is an image of the experimental results obtained in relation to Example 2. As shown in the FIG. 6, the clarity of the release water is directly correlated to the dosage of lime concentration. The improved clarity of the release water is an indication of reduced turbidity of the release water.
  • Table 1 shows results of Example 2 related to the settling time and the mudline.
  • the results in Table 1 indicate that as the concentration of lime addition was increased, (a) the settling time generally decreased and (b) the amount of settled solids, as indicated by the mudline, generally increased. Accordingly, the experimental results of Example 2 indicate that the amount of iime additive directly correlates to settling rate of the lime-FFT mixture. Hydrate Time to settle
  • Table 2 shows an analysis of the release water from Example 2. The results in Table 2 show that dissolved ion concentration varied for different concentrations of lime concentration addition. For example, calcium concentration of the lime treated FFT mixture initially dropped at the 750 mg/kg lime concentration, but increased at higher lime dosages and rose above the initial FFT calcium concentration once the pH exceeded 11.7.
  • Table 2 also shows an immediate reduction in the magnesium content, as magnesium concentration decreased from 12 mg/L to 1 mg/L at pHs above 10. Without being bound by theory, this is likely because a pH above 10 causes the magnesium to precipitate as g(OH)2, and is no longer soluble in the release water.
  • Table 2 also shows that carbonate alkalinity is indirectly correlated with lime concentration addition.
  • the initial alkalinity content of 882 mg CaCOs/L at the 0 mg/kg lime dosage decreases drastically to 118 CaCOa/L at the 750 mg/kg lime dosage, and then more gradually to 28 CaC03/L at the 1250 mg/kg !ime dosage.
  • the removal of carbonate alkalinity involves a first reaction which converts bicarbonates to carbonates by raising the pH from the hydrated lime addition, and a second reaction which reacts soluble calcium (from the initial process water or hydrated lime) with carbonate to precipitate calcium carbonate. The calcium carbonate then sequesters the calcium as an insoluble solid. Hydrated Disso ved !on Concentration Carbonate
  • the addition of lime in elevated concentrations provides benefits to the settling properties of the FFT solids.
  • the lime causes significant decreases in turbidity of the release water, which is an indication of enhanced capture of the clay particles of the FFT during flocculation.
  • the calcium particles of the lime react with the FFT to neutralize the anionic charges on the surface of the clays, which in turn coagulates the particles and improves flocculant performance. This is evident by the definitive mud line shown in FIG. 6 and captured in Table 1 above.
  • lime dosage that provides the quickest initial settling rate of the flocculated FFT.
  • the ideal lime dosage generally occurs after the carbonate alkalinity is substantially eliminated, but before soluble calcium concentrations rise to 90 mg/L.
  • This ideal lime dosage resulting in increased fines capture is represented by the slightly higher mudlines observed in FIG. 6 and shown in Table 1.
  • the slightly higher mudlines likely result because the solid bed in the lime treated FFT contains all of the solids treated in the experiment, whereas the solid bed from polymer only treatment may not include the fine clays suspended in the release water.
  • Trials 4 and 5 were conducted to examine the impact of increasing the percent solids of the pressure filter feed.
  • the FFT samples were diluted to 3% solids to simulate thickener feed.
  • Trial 4 utilized A3331 polymer (175 g/tonne) to flocculate the FFT and increase the underflow solids to 40%.
  • Trial 5 utilized approximately 2,000 mg/kg of hydrated lime, which was added prior to the A3331 polymer addition. The remaining hydrated lime of 2,000 mg/kg, which was required to achieve a pH over 12, was added to the 40% solids thickened underflow.
  • a first dosage of lime additive to a tailings stream to produce a first mixture having a pH iess than about 12.0 and a soluble calcium ievel less than about 100 mg/L;
  • adding the second dosage to the first mixture includes adding the second dosage to the second stream.
  • recycling the second stream is based at least in part on a measured soluble calcium level of the second stream.
  • At least one of the first or second dosages are part of a lime slurry including hydrated lime, wherein the hydrated lime includes particles having an average surface area greater than or equal to about 30 m 2 /g.
  • At least one of the first or second dosages includes a lime slurry comprising less than 15% lime by total weight.
  • forming a flocculant slurry by combining one or more polymers with at least one of process water or makeup water; and adding the flocculant slurry to the first mixture prior to adding the second dosage.
  • tailings stream includes bicarbonates
  • adding the first dosage of lime comprises reducing the bicarbonates in the tailings stream to be below about 20 mg/L.
  • a system for treating tailings streams for oil sands or mining operations comprising:
  • a tailings reservoir including tailings having about 3-40% solids by total weight; a first mixer positioned to receive a first lime slurry and the tailings from the tailings reservoir;
  • the dewatering device downstream of and in fluid communication with the second mixer, the dewatering device comprising at Ieast one of a centrifuge or filter;
  • adding the first lime slurry is based at Ieast in part on a pH of the first mixture being less than about 12.0;
  • adding the second lime slurry is based at least in part of a pH of the second mixture being greater than about 12.0;
  • a method for treating tailings streams comprising:
  • a first dosage of lime additive to a tailings stream to produce a first mixture, the first mixture having a pH less than about 12.0 and a soluble calcium level less than 100 mg/L;
  • the tailings includes a first total dissolved solids content and the first mixture includes a second total dissolved solids content less than the first total dissolved solids content.
  • the first mixture includes a magnesium content less than 20 mg/L.

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  • Water Supply & Treatment (AREA)
  • Hydrology & Water Resources (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
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  • Separation Of Suspended Particles By Flocculating Agents (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

Abstract

Cette invention concerne des procédés et des systèmes pour traiter des flux de queues de sables bitumineux à l'aide de multiples doses de chaux. Dans certains modes de réalisation, le procédé comprend l'utilisation d'un flux de queues contenant de 3 à 40 % en poids total de solides, la combinaison du flux de queues avec une première dose de chaux pour obtenir un premier mélange ayant un pH inférieur à 12,0, puis la combinaison du premier mélange avec un polymère pour obtenir un second mélange. Dans d'autres modes de réalisation, le procédé peut en outre comprendre la combinaison du deuxième mélange avec une seconde dose de chaux pour obtenir un troisième mélange ayant un pH supérieur à 12,0, et la déshydratation du troisième mélange dans une unité de centrifugation et/ou une unité de filtration par pression pour obtenir un flux de produit contenant 55 % en poids de solides ou plus.
PCT/US2018/059863 2017-11-08 2018-11-08 Traitement de flux de queues à l'aide d'une ou de plusieurs doses de chaux, et systèmes et procédés associés WO2019094620A2 (fr)

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US20230219832A1 (en) 2023-07-13
US11027995B2 (en) 2021-06-08
AU2018366144A1 (en) 2020-05-07
US20190135663A1 (en) 2019-05-09
US20210292198A1 (en) 2021-09-23
WO2019094620A3 (fr) 2019-07-11
AU2018366144B2 (en) 2024-05-09
CA3089959A1 (fr) 2019-05-16

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